A-ele-spe-800-30017-0

Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

Document Owner: Information ManagerRevision History Revision

Changes

A

Issued for Review & Comments (All changes are highlighted)

0

Issued for Design Abbreviation and Clause no. 2.2, 4.6, 4.16, 5.1, 5.2, 5.3, 5.6.2, 6.1, 6.3, 6.4, 6.5.2, 6.5.4 are updated.

This revision checked and signed off by: Name

Function or Job Title

Devidas Mahajan

Electrical Engineer

Sivagurunathan SP

Electrical Engineer

Prashant Gawas

Deputy Lead Electrical Engineer

Sudesh Waje

Lead Electrical Engineer

Madhav Deshpande

Lead Electrical Engineer

Timir Mehta

Project Engineering Manager

Mohammad Siddiquie

Project Engineering Manager

Holds Hold No.

Location

Description

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

Contents DOCUMENT OWNER: INFORMATION MANAGERREVISION HISTORY

2

ABBREVIATIONS

5

1

PURPOSE

6

2

REFERENCES

6

2.1 2.2

6 7

Codes and Standards CE Marking and Certificates

3

DEFINITIONS

4

GENERAL

10

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16

10 10 11 11 11 11 11 11 12 12 12 12 12 13 13 13

5

6

Ain Tsila Development - Summary Seller’s General Responsibilities Proven Equipment Design Life SITE SERVICE CONDITIONS Maintenance Interval Codes, Standards and Regulations Order of Precedence Tag Numbering Quality Assurance Health, Safety and Environmental Regulations Area Classification Language Deviations Hazardous Materials Material Health, Safety and Environment Data Sheets

8

TECHNICAL REQUIREMENT

14

5.1 5.2 5.3 5.4 5.5 5.6

14 15 15 15 15 16

General Freeze Protection System Design Process Heat Tracing System Operation Installation Design of Heat Tracing Components

HEAT LOSS CALCULATIONS

19

6.1 6.2 6.3 6.4 6.5

19 19 19 19 19

General Piping Systems Vessels and Storage Tanks Pumps Tracing cable Selection

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

7

ELECTRICAL POWER DSITRIBUTION

21

8

INSPECTION AND TESTING

22

8.1 8.2 8.3

22 22 22

General Factory Acceptance Test Field Acceptance Tests

9

ACCEPTANCE CRITERIA

23

10

PACKING AND PREPARATION FOR SHIPMENT

23

11

SPARE PARTS

23

11.1 11.2 11.3 11.4

23 24 24 24

12

General Start-up and Commissioning Spares Two Years’ Operating Spares Insurance Spares

DOCUMENTATION

25

12.1 12.2 12.3

25 25 25

General Documents and Information Required with the Tender Manufacturing Record Book

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

ABBREVIATIONS AISI

American Iron and Steel Institute

ATEX

ATmosphères EXplosibles (explosive atmospheres)

BS

British Standard

CE

Conformité Européenne (European Conformity)

CPF HV

Central Process Facility (the main reception, processing, utilities and storage systems) High Voltage (greater than 1000 V AC)

IEC

International Electrotechnical Commission

IP

Ingress Protection

ISO

International Organization For Standardization

FAT

Factory Acceptance Testing

P&ID

Piping and Instrumentation Diagram

EHT

Electrical Heat Tracing system

IEEE

Institute of Electrical and Electronics Engineer

Note:

BS Standards BS 6351-1:1983 Specification for electricsurface heating devices for EHT system Design, Manufacturer, Testing & Commissioning are superseded with BS EN 62395-1:2006, BS EN 60079-30-1:2007 and IEEE 515.

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

1

PURPOSE This specification covers the general requirement for design, material selection, manufacturing, testing, supply, painting preparation and installation & commissioning support of EHT system required for Ain Tsila Development project. While on the EHT Design, below points to be considered. Winterisation of instrument impulse lines and bridles as per marked up process P&IDs; Winterisation of supply piping, instrument lines and bridles as per marked up utilities P&IDs; Quantification of each circuit load demand and associated material take off; Provision of design criteria for specification of power distribution system from the local sub-station to the first junction box including circuit breaker characteristic and rating.

2

2.1

REFERENCES A-ELE-PHL-800-30001

Power system Design philosophy

A-ELE-SPE-800-30018

Specification – Electrical Requirements for Package Units

A-ELE-SPE-800-30015

Specification - Electrical Cables, Glands & Termination Kits

A-ELE-SPE-800-30012

Specification - Distribution Panels

A-ENG-BOD-00-30001

Basis of Design – Surface facilities

A-IMT-GLS-000-30002

Abbreviations and Units of Measurement

A-IMT-PRO-000-30005

Tag Numbering Procedure

A-INS-SPE-000-00010

Specification for General Instrumentation

A-PMT-ENG-000-30001

Specification – General Information

A-PRO-PHL-000-30006

Winterisation, Tracing and Insulation Philosophy

A-MTL-SPE-000-30008

Specification for insulation of Piping and Equipment

Codes and Standards Equipment supplied shall in addition to complying with national standards, also be in compliance with the following guides and recommended standards. Codes and Standards referred here shall be of the latest revision issued at the effective date 24th Dec. 2018 BS 6351

Electric Surface Heating

IEC 60364

Electrical Installations of Buildings

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

IEC 60800

Heating Cables with a Rated Voltage 300/500V for comfort heating and prevention of ice formatting

IEC 62395 -1

Electrical resistance heat tracing systems for industrial and commercial applications – Part 1: General and testing requirements

IEC 62395 -2

Electrical resistance heat tracing systems for industrial and commercial applications – Part 2: Application guide for system design, installation and maintenance

IEC 60079

Electrical apparatus for explosive gas atmospheres.

IEC 60079-30-1

Explosive atmospheres - Electrical resistance trace heating, General and testing requirements

IEEE - 515

IEEE Standard for the Testing, Design, Installation and Maintenance of Electrical Resistance Heat Tracing for Industrial applications.

IEC 60702-1

Mineral insulated cables and their terminations with a rated voltage not exceeding 750 V - Part 1: Cables

IEC 60702-2

Mineral insulated cables and their terminations with a rated voltage not exceeding 750 V - Part 2: Terminations

IEC 60702-3

Mineral insulated cables and their terminations with a rated voltage not exceeding 750 V - Part 3: Guide for use

Compliance with the referenced documents listed above does not relieve the SELLER of its responsibility to furnish equipment and services of proper design, workmanship, quality and materials to meet the specified and anticipated operating conditions and duties. Sole responsibility rests with SELLER for safe and reliable operation of the package / equipment during various operating and environmental conditions throughout plant life.

2.2

CE Marking and Certificates All equipment, materials and components included in the delivery for installation and application in the Ain Tsila Development shall be CE certified, shall have CE marking and shall be compliant to the EC directives, such as, but not limited to: •

•

Low Voltage o

Directive 2006/95/EC Low Voltage directive;

o

Guidelines for Safety of Low Voltage Equipment.

Explosive Atmospheres o

Directive 94/9/EC concerning equipment and protective systems intended for use in potentially explosive atmospheres (the ATEX Directive);

o

Guidelines on the application of Directive 94/9/EC;

o

Corrigendum on Directive 94/9/EC.

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

Seller shall provide the required explosion protection certificates in accordance with the ATEX 94/9 Directive. Seller shall provide an EC declaration of conformity, which shall state full compliance to the EC directives and standards. The declaration shall further state the method of compliance followed, e.g.: •

Self-certification to appropriate harmonized European standards;

•

Technical file, which is approved by an accepted, notified body;

•

Type examination.

CE marking and certification shall be applicable only for the equipment and components manufactured in European region. However, if equipments, components and systems are manufactured in other than European region; then vendor shall follow equivalent international standard which will be reflected in vendor documentation such as data sheets, GA drawing etc.

3

DEFINITIONS “COMPANY”

means Groupement ISARÈNE (the operator of the Ain Tsila development)

“CONTRACTOR”

means the party, which carries out all or part of the design, engineering, installation and commissioning, procurement and construction applicable to this specification

“Purchaser”

means the entity defined as such in the purchase order or contract

“Seller”

means the entity defined as such in the purchase order or contract

“shall” or “must”

indicates that the specified action is mandatory (i.e. must be done by the specified action party)

“should”

indicates that the specified action is recommended but not mandatory. However the action party will be responsible for the consequences in the event that he/she elects not to do it

“will”

indicates a commitment by others or a statement of fact

“Sub-supplier”

means the entity responsible for the supply of components or services to the Seller

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

“Manufacturer”

means the entity responsible for the manufacture of an item ultimately supplied by the Seller to the Purchaser

“Goods”

means the physical items delivered under the terms of the purchase order or contract

“Services”

means any services provided pursuant to the purchase order or contract but not incorporated in the Goods

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

4

GENERAL

4.1

Ain Tsila Development - Summary Groupement ISARÈNE (the “COMPANY”) will develop the Ain Tsila gas field which is located in the Illizi basin in the eastern part of the Sahara Desert in south-east Algeria, south of the Grand Erg Oriental. The field was discovered within the Périmètre Isarène (Blocks 228, 229a) in 2007 and has been appraised to hold approximately 65 billion cubic metres (2.29 trillion cubic feet) of recoverable hydrocarbon reserves. The field lies in the Sahara Desert, approximately 1,100km south-east of Algiers, 175km west of In Amenas, 175km north- west of Illizi and 450km to the south-east of Hassi Messaoud. Central Processing Facility (CPF) is designed to produce 10.3 MMSCMD sales gas. A gathering system, comprising wellsites, wellsite systems, flowlines, manifold stations and trunk pipelines to gather the produced fluids and transport them to the reception facilities at the CPF. Raw gas will be treated in the CPF. Processing facilities comprising pipeline reception facilities, slugcatcher(s), feed gas compression, mercury removal, gas dehydration, gas conditioning (natural gas liquids extraction), export compression, condensate stripper, LPG fractionation facilities, condensate and LPG export facilities and associated utilities, storage and buildings (all located at the CPF). Fiscal metering for sales gas, LPG and condensate, located at the CPF battery limit. Sales quality gas will be delivered to SONATRACH TRC’s (TRC) sales gas pipeline system at a tie-in point on a manifold next to the TFT compressor station. Liquefied petroleum gas (LPG) will be delivered to TRC’s LPG pipeline system at a tie-in point located at a block valve station west of the TFT compressor station. Stabilised condensate will be delivered to TRC’s condensate pipeline system at a tie-in point located at Méderba, approximately 165km north of Ain Tsila.

4.2

Seller’s General Responsibilities The Seller shall be fully responsible for all aspects of the design & engineering, manufacture, inspection, factory acceptance testing and supply of all equipment within its scope of supply. This shall include, but not be limited to:

•

•

Ensuring that the equipment meets all the requirements of this specification;

•

Co-ordination and control of its sub-Sellers, if any;

•

The provision of support to the Purchaser and COMPANY during FAT, commissioning and start-up;

•

The provision of a list of all appliances, special tools and accessories that are necessary for the correct installation, operation and maintenance of the equipment;

Seller shall complete the equipment data sheet(s) and return with its quotation.

Compliance with the provision of this specification does not relieve the Seller of its responsibility to furnish equipment of a proper design suited to meet the specified service conditions and/or local codes governing health and safety.

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

4.3

Proven Equipment The equipment rating, basic design and accessories shall not exceed the limits of the Seller’s proven design and shall not involve the use or application of any prototype design or component. Only equipment with demonstrable reliability is acceptable to COMPANY. The Seller shall provide application references with its tender which demonstrate a high level of reliability of the equipment proposed, in similar service under comparable operating conditions and in a similar location. At least two of the references must demonstrate at least 2 years of reliable operation.

4.4

Design Life The equipment shall be designed for a service life of 25 years.

4.5

SITE SERVICE CONDITIONS Heat tracing equipment & accessaries shall be suitable for successful operation in desert environment, with frequent sand storms and both elevated (+55 ˚C) and freezing (-5 ˚C) temperatures within a twenty four (24) hour period. Refer Basis of Design – Surface facilities (A-ENG-BOD-000-00001).

4.6

Maintenance Interval The equipment shall be designed to minimise maintenance, particularly that requiring a shutdown. The interval between major shutdowns shall be a minimum of 3 years.

4.7

Codes, Standards and Regulations The equipment shall be designed, manufactured, inspected and tested in accordance with the requirements of this specification, the documents referenced in Section 2, the equipment datasheets and appropriate Algerian regulations, codes and standards. The codes and standards used shall be the latest revisions available at the date of issue of the enquiry. The Seller shall include in its tender a detailed list of the codes and standards it proposes to use in the design and construction/fabrication of the equipment. These may include alternatives to those listed in Section 2, but such variances must be highlighted in its tender.

4.8

Order of Precedence The order of Precedence for all the Technical documentation shall be as follows: 1. Algerian Legislation and Regulatory Authorities Regulations 2. Project Philosophies 3. Equipment datasheets 4. Primary Equipment Specification 5. Other Project Specifications 6. International codes and standards Page 11 of 25

Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

In case of conflict between any of the above then the most stringent shall apply unless a dispensation has been approved by the COMPANY. Any deviations from these documents shall be agreed with the Purchaser prior to implementation. However, adherence to them does not relieve the Seller of its obligation to apply good industry practices in the delivery of goods and services to the Development.

4.9

Tag Numbering All equipment shall have tag numbers allocated in accordance with the Project Procedures. The Seller’s attention is drawn to the depth of tagging required and the information required to be supplied for each tag number. Dual tagging is permissible, such that the equipment carries a Project tag number and the Seller’s tag number. In this case the design of the Project tag labels shall be adjusted to accommodate the Seller’s tag number as well as the Project tag number.

4.10

Quality Assurance The Seller, and its sub-Sellers, shall operate a quality system satisfying the applicable provision(s) of ISO 9000 (2015 series) or, if agreed with COMPANY, an equivalent standard commensurate with the equipment provided. The Seller shall ensure that its sub-Sellers operate a quality system meeting the specified conformance criteria to ISO 9000. The Seller’s quality system will be subject to the Purchaser’s approval prior to issue of a purchase order. Major sub-Sellers will be subject to the same approvals. The Purchaser reserves the right to conduct a quality audit at the Seller’s/sub-Seller’s facilities at any stage during the design, manufacture, assembly, inspection and/or factory acceptance testing processes.

4.11

Health, Safety and Environmental Regulations The Seller shall be responsible for ensuring that the equipment supplied meets all applicable regulations on health, safety and environment.

4.12

Area Classification All equipment installed outdoors in the fenced area of the CPF, the well sites or any other outdoor hazardous area shall be certified for use in a Zone 1, Gas Group IIB, Class T3 hazardous area. All electrical equipment and materials shall be fully tested and certified by a CENELEC recognised certifying authority. All equipment supplied shall comply with the requirements of the ATEX directives. Type test certification shall be included with Sellers document package.

4.13

Language All documents, drawings and correspondence shall be provided in the English language. The system documentation, including the installation, operating and maintenance manuals, shall be provided in both English and French.

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

Where abbreviations are used on drawings, a legend shall be provided defining the abbreviations, in both English and French.

4.14

Deviations Any requirements herein which cannot be met shall be identified and variances explained in the Seller’s tender. Any non-conformances discovered (after purchase order placement or contract award) shall be formally notified by the Seller to the Purchaser and addressed through the Purchaser’s non-conformance and deviation processes.

4.15

Hazardous Materials Where the use of hazardous materials is unavoidable, the Seller shall provide the least damaging to personnel and the environment whilst ensuring the function of the equipment is not compromised. If this means providing an alternative to materials specified herein, these alternative materials shall be proposed to the Purchaser for agreement/rejection. Carcinogenic materials shall not be used.

4.16

Material Health, Safety and Environment Data Sheets If the equipment contains any substance that may be hazardous to health or the environment, then a material safety data sheet for each substance shall be provided by the Seller to the Purchaser. If the equipment does not contain any hazardous substances then a formal statement to that effect, signed by an authorised representative of the Seller shall be provided by the Seller to the Purchaser.

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

5

TECHNICAL REQUIREMENT

5.1

General Heat tracing design shall specify self regulating tape with options by formal exception only. Final heat trace sub-circuits shall comprise up to three (3) tapes connected to a junction box. Each secondary circuit shall comprise up to three junction boxes connected to a primary junction box, supplied via a discrete feeder circuit. However, Seller can propose their heat tracing ciruits designing as per IEC / IEEE standards. Heat trace primary circuits will be supplied and protectected by type “ C” miniature circuit breakers complete with thermal, magnetic and 30mA sensitivity residual earth fault protection. Individual auxiliary trip contacts shall be wired in series to provide and general alarm function by others. A thermal design safety factor of 25% shall be applied in all calculations. Heat trace system design shall: •

Provide heat tracing single line diagram from primary junction boxes to final tape;

•

Quantify heater length, ampere and total circuit load;

•

State Design criteria for local power distribution panel and circuit components;

•

Provide Material take off.

Design shall consider how best to remove, re-route or otherwise work on individual circuits with minimal electrical isolation. System design shall consider circuit thermostats for:

5.1.1

•

Efficiency;

•

Temperature control and limit.

Control on Ambient Temperature All local circuits may be controlled by a single thermostat to provide and ensure: temperature control and limitation.

5.1.2

Control of Pipe Surface Temperature Thermostats shall be calibrated by integral adjustment facility.

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

5.2

Freeze Protection System Design Design criteria shall be: •

Circuit energisation at 5 °C ambient;

•

Circuit de-energisation at 10 °C ambient;

•

Control via contactor circuit. (Ambient sensing controls)

Design criteria for freeze protection panels shall be provided by the Seller.

5.3

Process Heat Tracing System A coordinated and integrated electrical process heat tracing system shall be provided for systems where indicated in P&IDs. Maintained temperature lines/equipment shall have individual temperature sensors mounted on either pipe or equipment surfaces. Temperature monitoring equipment shall comply with IEC 60800.

5.4

Operation Any freeze protection control panel shall be capable of being operated in: •

Automatic Mode: o

•

Manual Mode: o

5.5

Circuit energization and isolation shall be initiated by a single temperature sensor with an adjustable dead band.

Circuit energized and isolation by selector switch at main incomer side Suitable interlock arrangement Auto / Manual selector switch with contactor shall be considered.

Installation Tracing shall be installed and connected in accordance with the installation instructions provided by the manufacturer. Cables that do not require to be spiraled shall be installed at the bottom of the pipe. External thermal insulation shall be installed immediately after insulation testing of the circuit. Insulation penetrations for control and feeder cables and capillary shall be installed

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

60 degrees below the horizontal pipeline to minimise the possibility of water ingress with suitable insulation entry kit. Tape efficiency requires maximum contact with pipe and equipment. For freeze protection, multiple heater cables may be operated in parallel from the same power circuit provided: •

The total, continuous branch circuit load at any time during operation shall not exceed 80% of the branch circuit breaker rating.

•

A maximum of five pipes or instrument lines are connected to the same circuit breaker.

Circuits for equipment which are supplied complete with heat-tracing and insulation such as eyewash stations, safety showers, instrument tubing bundles, and prefabricated instrument enclosures shall be powered and controlled directly from the local freeze protection control panel. 5.5.1

Thermostats (Mechanical) Temperature sensors shall, when mounted on a pipe, be positioned 60 degrees from heat trace tape and mechanically protected. Temperature sensors for on process lines shall be installed downstream of the tape.

5.6

Design of Heat Tracing Components

5.6.1

Heat Tracing Cable All electrical heater cable shall be self-regulating type with options by formal exception only. Self-Regulating / Self Limiting Heater Cable (SR / SL) cable shall consist of two stranded copper wires separated by a self-regulating conductive core. The core shall be covered by an inner insulating jacket, a tinned copper braid and an outer jacket with fluropolymer material. The heater cable shall operate on standard voltage of 230 V +6%-10% without use of special transformers. The design of the electric heater cable shall be such that it can be cut to any length in the field without changing the heat output per meter and shall not result in any small section of the pipe being without heat. The heater cable must be capable of being overlapped on itself without causing localized hot spots or creating any hazards or possibilities of burnouts. The heater cable shall be

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

capable of continuous and reliable operation when hanging loose in free air during equipment removal or replacement. Failure of controls while the heater cable is energized shall not raise the heater cable temperature sufficiently to cause heater cable failure. Seller is responsible for such limitation on design. The heater cable design shall be such that it can vary its output in response to temperature variations along a pipe for heat sinks such as pipefitting and supports, Seller needs to consider adequate heating cable allowances for the same as per their standards. The regulation of heat output with varying the temperature will be applicable for entire portion / segment of heating cable selected. Self-regulating heater cables shall be attached to pipes at maximum 30 cm intervals by means of fibre glass cloth tape having thermosetting electrical grade adhesive. Aluminium (adhesive type foil also shjall be used for valve, flange etc. All heater cables shall be installed on pipes in straight runs, without any spiralling.. Where additional heating is required, multiple cables shall be used. All heat tracing cable shall be installed on horizontal runs at minimum of 30° from vertical (11 o'clock or 1 o'clock) to prevent potential damage to heat tracing system. Cables shall be covered with a tinned copper Wire Braid for grounding and increased durability. The following shall be considered when selecting the heat tracing cable rating: •

Maximum withstand temperature of the heater shall be greater than the maximum possible equipment/instruments/pipework/tubing temperature.

•

Maximum allowable power density that can be used without damaging the equipment/instruments/pipework/tubing or its contents, especially critical in lined pipes and vessels containing heat sensitive materials.

Heat tracing cables shall be supplied in a continuous drum length. Minimum drum length will be 500 meters. Flexible blanket type heaters may be utilised on tanks and vessels having wire-wound resistance wires vulcanized between two layers of fibreglass reinforced silicone rubber. This shall be selected for the equipments / Vessels where installed under roof or free from rainfall / Water splash. 5.6.2

Junction Boxes for Heat Tracing cables Junction boxes shall be made of AISI 316 stainless steel / Glass reinforced plastic, certified Ex-e minimum IP54. Suitable inlet and outlet entries shall be provided for power cables / heat tracing cable.. Seller is to include within the MTO, a list of all glands required and specification criteria for power supply circuits in addition to those glands to be provided for all heater circuits. Individual terminals shall be provided for each conductor, with inter-connection of terminals on the same terminal block by proprietary links. Facilities shall be provided to ensure earth continuity for the termination of the integral earth conductor of Purchaser’s Page 17 of 25

Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

power cables and the earth conductor and/or braids in the heat tracing cables. Only one core per terminal is permitted, whilst all spare cores shall be terminated in spare terminals and earthed. Terminals shall be designed for terminating of conductors directly without the use of ferrules. All junction boxes/cables and heat tracing cables cores shall be ferruled, and numbered as per project procedure. Junction boxes shall be located optimisely in accessible areas for maintenance, typically not higher than 1.2 m above an accessible space. Junction box locations shall be selected to minimisedownstream power cables to the heat tracer JBs. Junction boxes shall be designed for mounting directly onto pipe work using adjustable stainless steel brackets. Insulation thickness and cable entry requirements shall be taken into consideration in the design of stainless steel brackets. 5.6.3

Power and Heat Tracing Cable Glands Cable glands, for cables to power junction boxes will be provided by the Purchaser. Glands for the heat tracing cable shall be provided by the Seller and shall meet the following requirements: •

Dual certified Protection: Ex e / Ex d

•

Gas group: IIB

•

Temperature class: T3

•

Ingress protection: IP55

•

Made of AISI 316 Stainless Steel or nickel plated brass.

Glands shall be equipped with a special seal to match the shape of the heating cable, a sealing washer to maintain the IP rating of the junction box, and a locknut.

5.6.4

Terminations Heating cable shall be terminated at their supply end, in a junction box located adjacent to the heat traced equipment/instruments/pipework/tubing. End seals shall be composed of two heat-shrinkable sleeves or shrouds having similar properties as the cable and being compatible with the sheath of the heat tracing cable, or be of the end cap/sealing compound type and shall be placed under insulation.

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

6

HEAT LOSS CALCULATIONS

6.1

General IEC 60079 Part-3 and IEEE 515 shall be followed as basis for the heat loss calculations. Software of the Seller of the tracing cables may be used when the calculation basis conforms to IEC / IEEE.

6.2

Piping Systems Seller is total responsible for detrmining heat loss for each electrical traced lines / tubes / vessels / equipment / tanks as per IEC / IEEE standards recommendation. Seller shall submit one sample heat loss calculation for one pipeline / tank / vessel as per IEEE standard along with techno-commercial bid. In the heat loss calculation, Following details shall be clearly explained. a. Application ratio b. Power output at maintained temperature with graph. c. Circuit design basis based on maximum length recommended for selected CB rating d. Conclusion.

6.3

Vessels and Storage Tanks Heat loss calculations shall be executed according to IEC 60079 Part-3 and IEEE 515. Detailed heat loss calculations of each item shall be handed over during the detailed design.

6.4

Pumps For the purpose of the heat loss calculations a pump may be simplified to a cylindrical vessel on supports.

6.5

Tracing cable Selection The required heat output of heater cable shall be determined by the calculated heat losses. The maximum continuous allowable sheath temperature of the tracing cable shall be selected on basis of the design temperature of the pipe or the design temperature of the vessel or the equipment being traced. Where the design temperature is substantially higher than the operating temperature,design specification shall consider intermittent allowable sheath temperature of the tracing cable. When the pipe temperature exceeds the maximum allowabl temperature of the heating cable, the double insulation technique can be considered. Correct combination of inner and outer layer of insulation material shall be determined by Seller. However, This will be submitted to for purchaser approval.

6.5.1

Vessels, Storage Tanks and Off-line Instruments Heating cable for total required trace length for vessels and tanks equals the sum of all losses divided by the available trace output at maintained temperature. The output power

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

of the trace shall be selected such that the area of the tank or vessel is covered till the maximum liquid height. The trace shall preferably be spiralled with a pitch of minimum 70 mm. Off-line instruments shall be traced with a separate heating cable as per instrument hook-up drawings. Seller can propose isolation switch for these offline instrument heat tracing. 6.5.2

Pumps The output power of the circuit shall be selected such that the required length covers the whole pump housing. The trace shall be wound around the housing such that the minimum distance between the tracers is not less than 70 mm, with the exception of those areas where extra losses occur.

6.5.3

Maximum Tracer Cable Length The maximum length of the cable shall be based on the recommendations of the manufacturer. The maximum trace length is equal to the nominal current of the circuit breaker divided by the inrush current at the switch-on temperature.

6.5.4

Cable Sizing The allowable current loading of the power supply cables shall be calculated conform the requirements of IEC 60364-5-523. The over current protection devices shall meet the requirements of IEC 60364-4. Cables shall be sized such that at a short circuit at the terminals of the most remote junction box is disconnected within five (5) seconds. The system voltage drop at the end of the most remote tracer cable shall be limited to 3%, calculated on basis of the nominal current of the protective device in the circuit.

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

7

ELECTRICAL POWER DSITRIBUTION Heat Tracing Distribution Board shall confirm to project specification and located outdoor near by heat tracing circuits location. Voltage drop shall be selected based on following criteria. Incomer to Heat Distribution Board – 2% Heat Tracing Distribution Board to Filed heat tracing circuit – 3% Cable selection shall confirm to project specification.

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

8

INSPECTION AND TESTING

8.1

General The responsibility for inspection rests with the Seller. The approval of any work by the Purchaser or the release of equipment for shipment shall in no way relieve the Seller of its responsibility for meeting the requirements of this specification. Inspection and testing shall be carried out in accordance with an approved project quality plan and shall comply with the requirements of this specification, the data sheets and other referenced documentation forming part of the purchase order. The Purchaser reserves the right to carry out its own inspection during design and manufacture. The Seller shall provide free access to its works, and to that of its subSellers, for the Purchaser and its authorised representative(s). All necessary certification documents relating to materials, shop test data, etc., shall be made available to the Purchaser and its authorised representatives to verify that the requirements of the purchase order are being met. The Seller shall furnish a representative quality plan detailing its normal scope of inspection and testing with its tender. In the event of an order, the Seller shall prepare a detailed project specific inspection and test plan for the Purchaser’s approval. The inspection and test plan shall identify all inspection and test activities, their acceptance criteria and Purchaser-observed or witness hold points.

8.2

Factory Acceptance Test Each circuit shall be given a continuity test to ensure that all components, instruments, and other devices are correctly wired. All the equipment shall be given a full functional check to verify performance criteria, sequence of operation to ensure satisfactory conditions. Factory inspections and tests for self-regulating heater cables shall include:

8.3

•

Dry dielectric spark tests at 6,000V on every meter of material shipped.

•

Resistance check as a function of temperature for every shipped length to ensure maintenance of proper heater characteristics.

•

Hand inspection on every meter of material shipped for cosmetic factors or visually detectable manufacturing defects.

Field Acceptance Tests Following test voltage shall be applied: 2 x Unom + 1000 Veff but at least 1500 V during 1 minute.

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

The test voltage applies to all components of the installation. In the field, all self-regulating heater cables shall be meggered with a minimum of 2500 VDC. The following separate field megger readings shall be taken on each self-regulating cable: •

Heater cable shall be meggered when received at jobsite before installation.

•

Heater cable shall be meggered after installation but before insulation is applied.

•

Heater cable shall be meggered after insulation has been installed.

All three of the above field megger readings shall be not less than 20 Mega ohms. Otherwise, the heater cable is not acceptable and must be replaced. Field megger tests shall be recorded for each heater cable, and certified reports shall be submitted.

9

ACCEPTANCE CRITERIA Will simply be successful completion of unit and system verification procedures outlined above.

10

PACKING AND PREPARATION FOR SHIPMENT Preparation of the Heat Tracing System shall be made after all inspection and testing of the equipment has been accomplished and the equipment has been released for shipment by the Purchaser. All exterior machined surfaces shall be coated with suitable rust preventative. All threaded openings shall have steel caps or solid-shank steel plugs. All necessary contract probes and instruments required for field termination shall be shipped installed. Small or fragile parts shall be removed, tagged, and wrapped in waterproof material, and packed in a box. Parts and accessories, when shipped separately, shall be prepared by the Seller in a manner to exclude moisture and damage when handled by commercial carriers and tagged with the Seller's order number and description. A packing list shall be placed both inside and the outside of the shipping package. Final and complete skid packaging shall consider transport conditions & long term external storage in a desert environment with frequent sandstorms. Space heater leads shall be accessible without disturbing the shipping package and shall be tagged for easy identification.

11

SPARE PARTS

11.1

General

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

Tenderers shall provide general quotations for the supply of start-up and commissioning/two years operational and insurance spare parts with the tender. The Seller shall provide itemised quotations, within sixty (60) days of order placement, for the following categories of spare parts with the tender: •

Start-up and commissioning spares (as recommended by the Seller)

•

Two years’ operating spares (for the entire package)

•

Insurance spares

Each of the above categories of spares shall be quoted by the Seller and an unpriced list included, in the technical portion of its tender, for review during the tender evaluation phase. Spares may be purchased separately or with the equipment. The spare parts list shall include parts location diagrams and drawings.

11.2

Start-up and Commissioning Spares Start-up and commissioning spares are those parts likely to be required during the installation, site testing and commissioning of the equipment, including minor modifications and damage repair. They shall include as a minimum:

11.3

•

One complete set of consumables

•

Delicate items likely to be broken during installation or testing

•

Any Special Tools (If applicable)

Two Years’ Operating Spares The Seller shall propose the spares required for two years’ operation of the equipment, based on ISARÈNE’s Maintenance and Sparing Philosophy (A-OPS-PHL-000-00002). This sets out the maintenance principles that COMPANY will apply in terms of the types of equipment that will be repaired at site, those types that will be scrapped and replaced as complete units and those that will be sent to the manufacturer’s service centre for repair. The proposal shall be set out on COMPANY’s spare parts interchangeability record (SPIR) form as specified in the Seller Documentation Requirements Schedule.

11.4

Insurance Spares Not applicable.

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Specification for Electrical Heat Tracing System Document No: A-ELE-SPE-800-30017 Revision 0

12

DOCUMENTATION

12.1

General The requirements for the Seller’s documents and data submissions are detailed in the Seller Document Requirements Schedule.

12.2

Documents and Information Required with the Tender The documentation and information listed below shall be included in the Seller’s tender: •

All Heat tracing components data sheets;

•

Estimated power demand;

•

Estimated architecture of HT system.

12.3

Manufacturing Record Book

12.3.1

General The Seller shall prepare a report on the tests carried out and their results, for inclusion in the manufacturing record book. Other relevant certificates shall also be included, together with the equipment release note. A complete set of as-built documentation shall be included.

12.3.2

Certificates of Conformity Shall be provided for all IP and hazardous area certified equipment.

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